English Français Deutsch Italiano Español. Users Manual. CAL 9500P Programmable Process Controller. CAL Controls

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1 Users Manual CAL 9500P Programmable Process Controller CAL Controls English Français Deutsch Italiano Español

2 English 2 INDEX INSTRUMENT PANEL FEATURES 2 FUNCTIONS MENU 3 GETTING STARTED 4 Initial Set-up 4 AUTOTUNE 4 Tune or tune at setpoint program 5 PROPORTIONAL CYCLE-TIME 5 Cycle-time recommendations 5 SECOND AND THIRD SETPOINTS (SP2 and SP3) 5 Error messages 6 LINEAR INPUT 6 Set-up procedure 6 FUNCTION LIST 7 Level 1 7 Level 2 7 Level 3 8 Output Options Table 8 Re-transmission 8 Level 4 9 Level A 10 RAMMER 11 Function overview 11 Getting started (Programmer) 12 Program run mode 12 Display functions 12 Example program 13 Function map 14 Function list 16 Memory allocation table 17 Memory full indicator 17 Programming example 18 Program edit example 18 MECHANICAL INSTALLATION 19 DIN panel cut-out 19 Mounting 19 Cleaning 19 ELECTRICAL INSTALLATION 19 Typical application 20 Input options (diagrams) 21 Output options (diagrams) 21 INPUT SENSOR SELECTION 22 Temperature sensors 22 Linear input 22 SPECIFICATION 22 SAFETY AND WARRANTY 23 INSTRUMENT PANEL FEATURES Green LED: Setpoint 1 output indicator Green Display: Process variable or Function/Option Upper Red LED: Setpoint 2 output indicator Lower Red LED: Setpoint 3 output indicator ADJUSTMENTS To enter or exit program mode: To scroll through functions: To change levels or options: To view setpoint units: To increase setpoint: To decrease setpoint: To reset latched alarm or tune fail: To run or Hold a program: This page can be photocopied and used as a visual aid and bookmark when! working in other parts of the manual. Right Red LED: Program Holdback indicator Orange Display: Setpoint value or program selection Press together for 3 seconds Press or Press together or together Press Press together Press together Press together briefly Press together for 3 seconds Notes: If in difficulty by becoming lost in program mode, press and together for 3 seconds to return to display mode, check the INSTRUMENT ADJUSTMENTS above and try again. When in program mode, after 60 seconds of key inactivity the display will revert to either inpt : none or, if the initial configuration has been completed, the measured value. Any settings already completed will be retained. During Program Configuration it is recommended that this feature is inhibited. Select ProG StAY in Level 4.

3 KEY OR TOGETHER TO CHANGE LEVELS OR OPTIONS FUNCTIONS MENU LEVL 4 LEVL 3 LEVL 2 LEVL 1 LEVL P Level C only visible when COMMS Option fitted LEVL C LEVL A DER.S DI.SS NO.AL LOCK SET.L USER-PROTECTED SETTINGS SP1.D SP2.D BURN REU.D REU.L SPAN ZERO CHEK READ TECH UER RSET CONFIGURE OUTPUT SAFETY SETTINGS CALIBRATION PERFORMANCE DATA Derivative sensitivity 0.1 to 1.0 x der.t (0.5) Display averaging dir; 1 to 32 (6) Disable -AL- alarm display ; on SP1 output device none; rly; SSd; AnLG Disable program auto-exit Auto; StAY SP2 output device none; SSd; rly; (read only) Security lock none; LEV 3; LEV 2; ALL Sensor burn-out Read SP1 output % up.sc; dn.sc; 1u.2d; 1d.2u Change program entry point 0 to 100% read only Off; on Reverse outputs SP1 manual output % 1r.2d; 1d.2d; 1r.2r; 1d.2r 0 to100% proportional mode only Reverse O/P LEDs Limit SP1 output % 1n.2n; 1i.2n; 1n.2i; 1i.2i Autotune or Park 100 to 0% Off; on; ParK; At.SP Span adjustment 0.0 to 25% sensor Limit SP2 output % SP1 Prop band (gain)/ full scale 100 to 0% hyst 0.1 deg to 100% Zero adjustment sensor f/s (10 C/18 F) Main SP2 mode 0.0 to 25% sensor full scale Integral time (reset) none; dv.hi; dv.lo; band; Off; 0.1 to 60 min FS.hi; FS.Lo; Cool; EoP Program number Set Monitor (5 min) 1 to 31 Second SP2 mode Off; on Derivative time (rate) none; LtCH; hold; Lt.ho; Run program Off; 1 to 200 sec nlin Read Monitor off; on; hold; del (25 sec) Display resolution VAr; hi; lo deg ins; CoPY; PStE Derivative approach 1 or 0.1 degree Power failure 0.5 to 5.0 x band Read Tune Data Set scale maximum CtA; Ctb; Ct1; Ct2; Ct3; Ct4; Instrument address recovery mode (1.5) 0.0 Sensor max to sensor os1; us; os2 0 to 255 rset; Cont; hold Cycle time or on/off On.off; 0.1 to 81 sec full scale Program start value Software version Baud rate (20 sec) PV; SP Set scale minimum Consult unit 1200; 2400; 4800 Offset (manual reset) 0.0 Sensor min to sensor 9600; 19k2 0 to 50% x band full scale Setpoint ramp time units RESET (In.t = off) Data format hour; 60s Select input sensor none; ALL 18n1; 18E1; 1801 Setpoint lock (SP1) none High scale to 9999 Segment number Off; on TxRx activity 1 to 126 max. Select display units Off; on Adjust SP2 setpoint none; C; F; bar; Low scale 0 Define segment type +/ sensor full scale or PSi; Ph; rh; SEt to 9999 SPr; SoAK; StEP; LooP; full scale Call; EoP; del; ins SP2 prop band/gain/ Input high 50.0 Setpoint ramp rate Hyst 0.1 deg to 100% 0.1 to to 9990 (100) sensor f/s (2 C/3.6 F) units/time Input low 10.0 SP2 Cycle on/off Adjust target setpoint 0.0 to 49.9 On.off; 0.1 to 81 sec +/ sensor full scale or full scale Decimel or Soak time interval Holdback value Cont; 0.1 to 1400 off; 0.1 to 150 Main mode none (10) min dv.hi; dvlo; band; Fshi; Event output (SP2A or SP3A) FSLo; EoP Program re-cycle count none; 2d; 2E; 3d; 3E; 2d.3d; Cont; 1 to 999 2E.3d; 2d.3E; 2E.3E Second mode none LtCh; hold; Lt.ho Call sub-program number none; 1 to number Set SP3 0 of programs 0 to 2500 Hysteresis SP % sensor full scale Burnout SP3 - upsc dhsc Reverse O/P3 3D 3r SP1.P HAND PL.1 PL.2 SP2.A SP2.B DISP HI.SC LO.SC INPT UNIT MANUAL ADJUSTMENTS SP2 MODES RANGING CONFIGURE INPUT TUNE BAND INT.T DER.T DAC CYC.T OFST SP.LK SET.2 BND.2 CYC.2 RAM ENTRY (DEFAULT) SP1 SETTINGS SP2 SETTINGS RUN FAIL ST.U SPRU SPRR T.SP HB.V EO.P RAMMER SETTINGS ADDR BAUD DATA DBUC AN.HI ANLO COMMS SETTINGS SINT PCYC SUB.P HI.IN LO.IN DECP SP3.A SP3.B SET.3 HYS.3 BRN.3 REV.3 This page can be photocopied and used as a visual aid and bookmark when!working in other parts of the manual. \\ INITIAL SET-UP ENTRY Range of Adjustment shown under description. If applicable, factory settings shown in bold. For a full description of menu functions refer to pages 7 to 10, and 16/17 in Programmer section. Note: The letter K appears in the instrument display as the character K English LINEAR SCALING AND INPUT SETTINGS SP3 MODES KEY OR TO VIEW FUNCTIONS SP3 ADJUSTMENTS SP3 SAFETY SETTINGS 3

4 English 4 GETTING STARTED After power-up the controller requires programming with the following information: Type of Sensor (See list of sensors p.22) Operating unit C F bar PSi Ph rh SEt Allocation of Output Device to SP1/SP2 (Relay / SSd) or analogue. SP3 is always relay. Setpoint When the above information has been programmed into the controller it will be operational with factory PID settings. INITIAL SET-UP On power-up the controller will display the self test sequence followed by the initial display inpt : none 1 Select input sensor. Press and hold and use the or buttons to scroll through the sensor selection list until the correct sensor is displayed. Release the buttons. The display will now read selected sensor type e.g. inpt : tcs (type S thermocouple). Press once The display will now read unit : none LINEAR INPUT When Linear Input is selected, the display resolution of the setpoint and many other functions will be changed from the setting previously made at di.sp in Level 2, to that set at decp in Level A. It is therefore recommended that on completion of the Initial Set-up the Linear Input settings in Level A be completed before moving on to configure Levels 1, 2 and 3. (see Set-up Procedure page 6). 2 Select operating unit. Press and hold and use the or buttons to scroll through the unit selection list until the correct unit is displayed. Release the buttons. The display will read selected unit e.g. unit : C Press once The display will now read SP1.d : none 3 Select SP1 (Main setpoint output device) Analogue output The allocation of the analogue output to SP1 automatically overrides the default proportional cycle time setting of 20 seconds. Where the analogue output is allocated to SP2, the default CyC.2 setting on/off must be manually changed in Level 1 to a time proportioning setting to enable the analogue output to operate in proportional control mode. Press and hold and use the or buttons to select from the choices Rly, SSd or AnLG depending on the model supplied. SP2 and SP3 outputs will be automatically allocated. (See output options table on page 8). 4 To enter initial configuration into controller memory Press and hold both and buttons for 3 seconds. The display will now read PArK and measured variable (e.g. ambient temperature 23 ). PArK is displayed because a setpoint has not yet been entered. To display setpoint units Press and hold The displays will now read unit (eg. C ) and 0 To enter setpoint Press and hold and use button to increase or button to decrease the reading and scroll to required setpoint value. (The digit roll-over rate increases with time). THE CONTROLLER IS NOW OPERATIONAL WITH THE FOLLOWING FACTORY SETTINGS Proportional band/gain 10ºC/18ºF/100 units Integral time/reset 5 mins Derivative time/rate 25 secs Proportional cycle-time 20 secs (Typical setting for relay output) DAC Derivative approach control 1.5 (Average setting for minimum overshoot) Note: For more precise control or for non temperature applications where a Linear input transducer is being used, the controller may need to be tuned to the process. Please refer to the following section on AUTOTUNE. AUTOTUNE This is a single shot procedure to match the controller to the process. Select either Tune or Tune at Setpoint from the criteria given below. The Tune program should be used for applications other than those listed under Tune at Setpoint below. The procedure will apply disturbances when the temperature or process reaches 75% of the setpoint value, causing overshoot which is monitored in order to adjust the DAC overshoot inhibit feature. Care should be taken to ensure that any overshoot is safe for the process. The Tune at Setpoint program is recommended when: The process is already at setpoint and control is poor The setpoint is less than 100 C in a temperature application Re-tuning after a large setpoint change Tuning multi-zone and/or heat-cool applications. Notes: DAC is not re-adjusted by Tune at setpoint. Proportional Cycle Time can be preselected before running the Autotune program. (see page 5).

5 AUTOTUNE (continued) Hereafter in the Manual the symbol ( ) signifies both buttons are held pressed for 3 seconds to ENTER or EXIT Program mode. TUNE OR TUNE AT SETPOINT RAM Enter program ( ) and from the display tune : off press and hold and press to display tune : on or tune : At.SP Exit program mode ( ). The TUNE program will now start. The display will show tune as the process variable climbs to setpoint. Note: Avoid tuning while running a program as SP1 may be different from the target setpoint.. When the TUNE or TUNE AT SETPOINT program is complete the PID values are entered automatically. The process will rise to setpoint and control should be stable. If not, this may be because optimum cycle time is not automatically implemented. To set the cycle time see PROPORTIONAL CYCLE-TIME. PROPORTIONAL CYCLE-TIME The choice of cycle-time is influenced by the external switching device or load. eg. contactor, SSR, valve. A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro-mechanical switching device. Factory set To use the 20 sec factory set cycle-time no action is needed whether autotune is used or not. To Manually Select AUTOTUNE Calculated CYCLE-TIME When AUTOTUNE is completed, enter program ( ) and select CYC.t in Level 1. The display will read CYC.t : 20 (the factory setting). To view the new calculated optimum value, press and hold both and buttons until indexing stops. The calculated value will be displayed eg. A16. If acceptable, exit program ( ) to implement this setting. To Pre-select Automatic Acceptance of AUTOTUNE Calculated CYCLE-TIME Before AUTOTUNE is initiated select CYC.t in Level1, press and hold both and buttons until indexing stops at A. Exit program ( ) to accept calculated value automatically. To Manually Pre-select Preferred CYCLE-TIME Before AUTOTUNE is initiated select CYC.t in Level 1, press and hold both and or buttons until indexing stops at preferred value then exit program ( ) to accept. CYCLE-TIME RECOMMENDATIONS Output Device Factory Setting Recommended Minimum Internal relays 20 seconds 10 seconds Solid state drives 20 seconds 0.1 seconds SECOND AND THIRD SETPOINTS (SP2 and SP3) PRIMARY ALARM MODES Configure SP2 output to operate as an alarm from SP2.A in Level 2 and set the alarm setting in SEt.2 Level 1. Configure SP3 alarm mode SP3.A and setting SEt.3 in Level A. The alarms will be individually triggered when the process value changes according to the options listed below. dv.hi Rises above the main setpoint by the value inserted at SEt.2/3. dv.lo Falls below the main setpoint by the value inserted at SEt.2/3. BAnd Rises above or falls below the main setpoint by the value inserted at SEt.2/3. FS.hi Rises above the full scale setting of SEt.2 or SEt.3. FS.Lo Falls below the full scale setting of SEt.2 or SEt.3. EoP Event Output (See Programmer section pages 11 to 18) SUBSIDIARY SP2 / SP3 MODES The following additional Subsidiary alarm functions can be added to any Primary alarm configurations using the settings found at SP2.b in Level 2 and SP3.b in Level A. LtCh Once activated, the alarms will latch and can be manually reset when the alarm condition has been removed. Hold This feature inhibits alarm operations on power-up and is automatically disabled once the process reaches the alarm setting. Lt.ho Combines the effects of both LtCh and hold and can be applied to any Primary alarm configuration. SECOND SETPOINT (SP2) Proportional control output Configure in Level 1 using CyC.2 to select proportional cycle time and bnd.2 to adjust proportioning band. For Heat/Cool operation see Operating Manual. Additional in depth information on controller operation is available in the CAL 9400.PDF available for down load from In on off mode, bnd.2 adjusts SP2 hysterisis. Alarm type On-Off operating mode SP2 and SP3 Proportional operating mode SP2 only Deviation DV.HI DV.LO BAND Full scale FS.HI FS.LO COOL Strategy Output state LED state Output state LED state BAND Temperature above setpoint : on-off mode only Legend Output ON (Relay or SSd energised) Output OFF (Relay or SSd de-energised) LED ON 5 English

6 English SP2 / SP3 OUTPUT AND LED STATUS IN ALARM CONDITION SP2 / SP3 ALARM ANNUNCIATOR If a Primary Alarm mode has been configured, when an alarm condition occurs the alarm annunciator -AL- will be displayed alternating with the process variable. The alarm together with the display, will be automatically reset as soon as the alarm condition has been cleared. The annunciator may be disabled by selecting no.al: on, in Level 4. ERROR MESSAGES SENSOR FAULT Display flashes: inpt: FAiL Indicates: sensor open or short circuit or linear input over-range. Action: Check sensor/wiring/connectors NON-VOLATILE MEMORY ERROR Display flashes: data : FAiL Action: De-power briefly. Replace unit if problem persists MANUAL POWER ERROR Display flashes: hand : FAiL SP1 set to on off in CYC.t Action: Select proportional mode IMMEDIATE FAIL ON AUTOTUNE START Display flashes: tune : FAiL Setpoint display 0 1. No setpoint entered. Action: Enter setpoint 2. SP1 set to ON/OFF in CyC.t Action: Select proportional mode Note: To reset and clear error press together briefly to cancel message. FAIL LATER DURING AUTOTUNE CYCLE The thermal characteristics of the load exceed the Autotune algorithm limits. The failure point indicated by any display 0.0 in tech e.g. Ctb = 0.0 Action: 1. Change the conditions. eg. raise setpoint 2. Try tune : At.SP 3. If the error message persists, call local CAL representative for advice. LINEAR INPUT Set-up Procedure The 4 20mA input model converts current into voltage using an internal resistor which spreads the signal across the input range 10 to 50 mv. using multiplier of 2.5. When using a transducer with an output less than 4 20mA, the input maximum and minimum mv values can be calculated using the same multiplier. Models with 0 to 5V input use an internal resistor to spread the signal across the input range 0 to 50 mv using a divider of 100. Where a transducer provides a smaller output, the input maximum and minimum values can be similarly calculated. Decide what scale minimum and maximum will be required, and whether the scale needs inverting. (See Level A; Linear Input Scaling for list of settings and limits, page 10). The example below shows how a 4 20mA linear Input should be configured. # e.g. 4 20mA = 60 to 260 units where 4mA = 60 units Follow INITIAL SET-UP procedure (also see page 4). 1. Select input sensor Select inpt:lin 2. Select unit Select required unit, if not available Select unit:set 3. Select SP1 output Select from: Rly, SSd or AnLG Enter initial configuration into controller memory DO NOT ENTER SETPOINT until Linear Input has been configured in Level A See functions menu page 3 and functions list page 10. Configure Linear Input Enter level A (Then using example given # above) 4. Enter scale maximum Select An.hi: Enter scale minimum Select An.Lo:60 6. Enter input maximum Select hi.in: Enter input minimum Select Lo.in: Enter display resolution Select decp:0000 (WARNING otherwise settings marked may be altered) Enter Linear Input configuration into controller memory and enter setpoint. Now configure Levels 1, 2 and 3 and if required proceed with AUTOTUNE. Note: Any apparent calibration errors can be removed using the ZEro and SPAn adjustments in Level 3. 6 Will be affected by decp settings in Level A

7 FUNCTION LIST (LEVELS 1 to 4 and A) Note: A Functions Menu is shown on page 3. LEVEL 1 Function Options [Factory settings] shown in brackets SELECT AUTOTUNE (see pages 4/5) tune [off] on PArK At.SP Used to switch the Autotune feature on and off, to select PArK or Autotune at setpoint. PArK temporarily turns the output(s) off. To use select PArK and exit program mode. To disable re-enter program at tune and select off. SP1 OPERATING PARAMETERS band 0.1 to * C/ F [10ºC/18ºF/100 units] SP1 proportional band/gain or Hysteresis * 100% (Hi.Sc) sensor maximum Proportional control eliminates the cycling of on-off control. Output power is reduced, by time proportioning action, across the proportional band. LEVL 1 int.t off 0.1 to 60 minutes [5.0] SP1 integral time/reset Auto-corrects proportional control offset error der.t off seconds [25] SP1 derivate time/rate Suppresses overshoot and speeds response to disturbances dac x band [1.5] SP1 derivative approach control dac Tunes warm-up characteristics, independent of normal operating conditions, by adjusting when derivative action starts during start-up (smaller dac value = nearer setpoint). CyC.t A on.of sec [20] SP1 proportional cycle-time (see pages 9/10) Determines the cycle rate of the output device for proportional control. Select on.of for ON/OFF mode. ofst 0 to * C/ F/units [0] SP1 offset/manual reset * ±50% band. Applicable in proportional and ON/OFF mode with integral disable: Int.t : off. SP.LK [off] on Lock main setpoint Locks the setpoint preventing unauthorised adjustment. bnd * C/ F/units [2.0 C/3.6 F 2 units] Adjust SP2 hysteresis or proportional band/gain (see CyC.2 setting) * 100% sensor f/s (Hi.Sc) CyC.2 [on.off] seconds Select SP2 ON/OFF or proportional cycle-time Select on.off for ON/OFF mode, or the cycle rate of SP2 output device for proportional mode. LEVEL 2 MANUAL CONTROL MODES Function Options [Factory settings] shown in brackets SPI.P 0 to 100 % read only Read SP1 output percentage power hand [off] 1 to 100 % (not in ON/OFF) SP1 manual percentage power control For manual control should a sensor fail. Record typical SP1.P values beforehand. PL to 0 % duty cycle [100] Set SP1 power limit percentage Limits maximum SP1 heating power during start-up and in proportional band. PL to 0 % duty cycle [100] Set SP2 percentage power limit (cooling) SP2 OPERATING MODES (see page 5) SP2.A [none] Main SP2 operating mode Will be affected by decp settings in Level A SP2 OPERATING PARAMETERS (see page 6) Function Options [Factory settings] shown in brackets SEt.2 [0] to * C/ F/units Adjust SP2 setpoint * Deviation Alarms DV.hi, DV.Lo, band 25% sensor maximum. * Full scale alarms FS.hi, FS.Lo sensor range f/s LEVL 2 SP2.b [none] LtCh hold nlin Subsidiary SP2 mode: latch/sequence Non-linear cool proportional band dv.hi dv.lo band FS.hi FS.Lo Cool EoP 7 English

8 English LEVEL 2 CONTINUED INPUT SELECTION AND RANGING di.sp [1] 0.1 Select display resolution: for display of process value, setpoint, OFSt, Set.2, hi.sc, LoSC. hi.sc [sensor maximum] sensor maximum C/ F/units Set full scale Lo.SC [sensor minimum] sensor minimum C/ºF/units Set scale minimum (default 0 C/32 F or 0 units) Re-transmission * These models above offer the option of using the analogue output for Re-transmission. Select band or bnd.2 value in LEVL 1 to equal the full range setting in LEVL A and if using SP1 output, set int.t and dert.t in LEVL 1 to off. Example: Set-Up using a Model 95B11P to Re-transmit the 4-20 ma input, scaled 0 to 100 units. SP1 relay is used as the control output and SP2 analogue output is used for retransmission. Note: Read in conjunction with Linear Input Set-up Procedure on page 6. inpt Select input sensor [none] (See SENSOR SELECTION table, page 22) NB. If Linear Input selected, start configuration from Level A. 8 unit [none] C F bar Psi Ph rh SEt Select required operating unit from above options LEVEL 3 LEVL 3 OUTPUT CONFIGURATION Note 1: Read only after initial configuration. rset ALL full reset to factory settings required to change SP1.d subsequently. Note 2: Depending on the Model, SP1 and SP2 may be fitted with any of three output types, RLY, SSd or Analogue (Specification on page 11/12) where appropriate, these must be allocated during initial configuration. SP3 is always fitted with RLY. Output Options Table Model SP1 Output SP2 Output SP3 Output 95111P RLY RLY RLY 95001P SSd RLY RLY RLY SSd RLY 95221P SSd SSd RLY *95X11P AnLG RLY RLY RLY AnLG RLY *95X21P AnLG SSd RLY SSd AnLG RLY * Substitute for X in table above, Analogue options B = 4 20mA, C = 0 5V, D = 0 10V Will be affected by decp settings in Level A Function Options [Factory settings] shown in brackets From initial power-up; Set inpt none to inpt Lin unit none to unit SEt (for example) SP1.d none to SP1.d rly To scale the input, select LEVL A, then: Set decp to (e.g. required resolution) An.hi to An.Lo to 0.0 hi.in to 50 (ie 20mA) Lo.in to 10 (ie 4mA) To align SP2 analogue re-transmission with SP1 control output, select LEVL 2 then: Set SP2.A to FS.hi And in LEVL.1 Set SEt.2 to 50 (ie 50% of display range) bnd.2 to 100 (ie 100% of display range) Finally, set SP1 setpoint value as required for process to start. Using SP1 output for re-transmission Set int.t to off dert to off rev.d to 1d.2d to invert SP1 output SP1 Setpoint to midscale burn Sensor burn-out/break protection Caution: Settings affect fail safe state. SP1 SP2 [up.sc] Upscale Upscale dn.sc Downscale Downscale 1u.2d Upscale Downscale 1d.2u Downscale Upscale Retransmission range is limited to the sensor full scale value (Example RTD = 400C/752F).

9 LEVEL 3 CONTINUED Function Options [Factory settings] shown in brackets reu.d Select output modes: Direct/Reverse Caution: Settings affect fail safe state. SP1 SP2 [1r.2d] Reverse Direct 1d.2d Direct Direct 1r.2r Reverse Reverse 1d.2r Direct Reverse reu.l Select Reverse on SP1 for heating and Direct for cooling applications. Select SP1/2 LED indicator modes SP1 SP2 [1n.2n] Normal Normal 1i.2n Invert Normal 1n.2i Normal Invert 1i.2i Invert Invert SPAn [0.0] to ±25% sensor maximum in Linear Sensor span adjust For recalibrating to align readings with another instrument e.g. External Meter, data logger. See Full Operating Manual (ADVANCED SETTINGS). ZEro [0.0] to ±25% sensor f/s in Linear Zero sensor error (see Sensor span adjust above). ChEK [off] on Select control accuracy monitor read [Var] hi Lo Read control accuracy monitor tech [Ct A] CT b Ct 1 Ct 2 Ct 3 Ct 4 os 1 us os 2 Read Autotune tuning cycle data (see Operating Manual) UEr Software version number rset [none] ALL Resets all functions to factory settings Caution: This selection will lose all of the current settings. LEVEL 4 Access to level 4 is gained through UEr in level 3. Press and hold and for 10 seconds. Enter level 4 at Lock, release and together. Display reads LoCK none Program security using Lock [none] Select from three Lock options: Press and hold, press to index. LEV.3 LEV.2 locks level 3, 4, A (and C when fitted) locks level 2, 3, 4, A (and C when fitted) ALL locks all functions (including C when fitted) Note: Any locked functions and options can still be read. Press to access following functions. Function Options [Factory settings] shown in brackets ProG [Auto] StAY Program mode auto-exit switch Auto-exit returns display to normal if 60 seconds of key inactivity, select StAY to disable no.al [off] on Disable SP2 alarm annunciator -AL- Select on to disable -ALdi.SS dir 1 to 32 [6] Display sensitivity dir = direct display of input 1 = maximum, 32 = minimum sensitivity der.s 0.1 to 1.0 [0.5] Derivative sensitivity SEt.L (off) on Remember next menu exit point and use as new menu entry point, except when exit is in Level 1. LEVEL P LEVL P See RAMMER Section, page 11. LEVEL C LEVL 4 LEVL C COMMS SETTINGS; visible only when Comms option fitted. English Will be affected by decp settings in Level A Additional in depth information on controller operation is available in the APPGUIDE.PDF available for down load from 9

10 English LEVEL A LEVL A Function Options [Factory settings] shown in brackets Linear Input Scaling Please read in conjunction with Linear Input Set-up Procedure on page 6. An.hi to 9999 [1000] Adjusts required scale maximum An.Lo to 9999 [0] Adjusts required scale minimum hi.in 0.1 to 50.0 [50.0] Configure input maximum Function Options [Factory settings] shown in brackets brn.3 [upsc] upsc or dnsc Sensor burn-out / break protection Select upscale or downscale rev.3 [3d] 3d or 3r Reverse SP3 output mode Select direct or reverse operation Lo.in 0.0 to 49.9 [10.0] Configure Input minimum This setting must be at least 0.1 less than the setting for hi.in above. Note: Refer to Linear Input conversion factors detailed in the Set-up Procedure on page 6. decp to [0000] Scale resolution NB. Once the Linear Input option has been selected, the setting here over-rides the scale resolution setting di.sp in Level 2 and will affect the following display readings: Level A: An.hi; An.Lo; Set.3; hys.3 Level 1: band; ofst; SPrr; SEt2; bnd.2 Level 2: hisc; LoSC Level 3: SPAn; ZEro; read; tech SP3 SETTINGS SP3.A [none] Main SP3 operating mode dv.hi dv.lo band FS.hi FS.Lo EoP SP3.b [none] LtCh hold Lt.ho Subsidiary SP3 operating mode SEt.3 0 to 2500 [0] SP3 setpoint adjustment hys to 100% of hisc [20] Set SP3 hysteresis 10 Will be affected by decp settings in Level A

11 RAMMER INDEX Function overview 11 Getting started 12 Program run mode 12 Display functions 12 Example program 13 Function map 14 Function list 16 Memory allocation table 17 Memory full indicator 17 Programming example 18 Program edit example 18 FUNCTION OVERVIEW The Programmer function in Level P enables the Model 9500P to control applications needing Setpoint changes over time. Examples of this are Ramp changes where a gradual Rate of change can be set, or Step changes which are instantaneous. These can be separated by Soak periods during which the process is held at a constant value. Each individual time interval of the program or Segment, together with it s associated moving setpoint value can be stored as a unique Program and for example be represented by the diagram below. Setpoint Ramp Soak Step In addition to those settings that determine the segment profile, it is also necessary to set program start values, together with the preferred ramp rate time units for each individual program. At the end of a sequence, a Program can be arranged to repeat (Loop), either a specified number of Cycles, or continuously. Only one Loop can be included in a Program. When the program is running, the Display indicates progress through the sequence of segments, and can additionally be interrogated for further segment information. It is also possible to CALL an already existing program as a sub program that can be inserted as a segment of another program. To speed up Program configuration, several Edit functions have been provided so that individual Segments and Programs may be Deleted or Inserted, and an entire Program may be Copied and then Pasted into another that it will replace. For safety reasons, three modes of recovery from a power failure are available. These either automatically Re-start the Program from the beginning, Continue it from where it stopped, or Hold it waiting for a user re-start. Either one or both of the two auxiliary outputs can be configured as Event outputs. Engaging the Holdback feature will temporarily halt Setpoint ramping to allow the process temperature to catch up should it deviate by more than a pre-set amount during a Ramp segment. To afford maximum programming flexibility, memory is allocated dynamically, and not preallocated. This allows the user the freedom to configure a small number of long programs or a larger number of shorter ones, up to the permitted maximum of 126 Segments per program, and a limit of 31 Programs. Should these limits be exceeded, or the Programmer memory become fully used, the display will read ProG FULL. Programs can be planned using the Memory Allocation Table which details the memory requirements of individual segment types. During configuration a check can be kept on memory usage by interrogating the USEd feature of the display to give an instant reading of percentage memory used. Finally, once a program has been configured, it can be run from the run off/on/hold controls in Level P, and in addition a quick access run/hold toggle is directly available from the front panel. The Programmer Functions List describes the full range of available Settings for each Programmer Function together with their display mnemonic. The Model 9500P is supplied with a suite of Factory Settings for each Function. These are shown in bold type. The Functions Map illustrates the relationship between the Functions and their Settings and provides a guide to the Keying Operations required to navigate around the menu when configuring or running a Program. English Time (Segments) 11

12 GETTING STARTED (RAMMER) For users with previous experience of configuring programmers, the 12

13 EXAMPLE RAM SPR Temp SPRR SOAK SINT STEP T.SP SPR SPRR LOOP PCYC SPR SPRR SOAK SINT STEP T.SP SPR SPRR English T.SP 137 Soak Function Interval: 45 mins T.SP 30 T.SP 137 T.SP 30 Ramp Function Rate, 105 deg/hour Target setpoint: 137 deg Step Function Target setpoint: 85 deg Ramp Function Rate, 55 deg/hour Target setpoint: 30 deg STOP 30 Loop Function Number of repeat program cycles: Time 3 See segment configuration of this program detailed on page

14 English RAMMER FUNCTION MAP START HERE Press and hold for 3 seconds ENTER RAM Paste only appears after a program is copied EDIT PSTE 3 secs SURE NO SURE YES 3 secs 3 14 If COMMS option fitted, LEVEL C appears between LEVEL P and LEVEL A LEVL C TUNE OFF LEVL 1 LEVL P LEVL A Add new programs at top of existing menu To view existing programs 1 to 31 or full? ADD USED 0 Program 3 now appears in list To add new program, press once RUN OFF Copies the selected program Program editing functions. Insert Program editing functions. Delete Hold the program at current position Start program when on selected. This locks other options out EDIT COPY EDIT INS EDIT DEL RUN HOLD RUN ON Hold the program at the point it stopped Continue the program from where it stopped FAIL HOLD FAIL CONT Reset the Program program at off state beginning RUN FAIL ST.V OFF RSET PV Select the required program number. Default: 1 Memory used (%) 3 secs 3 secs 3 secs Select program mode of operation Default: off 1 2 SURE NO Power failure recovery position Default: reset A copy of program 1 can be pasted into another program Another program has been inserted into 2 re-numbering existing 2 to 3 SURE YES Options: start program at main SP or process variable 3 secs ST.V SP Select the starting point of program after power up Default: PV Program 1 has been copied to program 3 2 Program 3 has been deleted. Display shows next program down from top of list Options: hours minutes SPRU 60 S SPRU HOUR Ramp rate time units adjustment Default: hour

15 Insert new segment in the menu EDIT INS 3 secs 2 New segment now inserted into 2. Old segment 2 becomes 3 Event output options energise and de-energise for all combinations of SP2 & SP3. E.OP 2D3E E.OP 2E3E English Delete a segment EDIT DEL 3 secs SURE NO SURE YES 3 secs 2 Segment 3 deleted E.OP 2E3D Add new segments at top of existing list To view existing segments 1 to 126 or full? ADD 2 3 Segment 3 now appears in menu 1 To add new segments press once SPR Event output Call up another program Program re-cycles Step Soak Ramp E,OP CALL LOOP STEP SOAK SPR Soak time in minutes or continue Default: 10 Important note Up button must be used after selecting the segment type to confirm it s selection SUB.P NONE PCYC 1 SINT 10 SPRR 100 Define the program number called Default: none Set Numbers of re-cycles 1 to 999 unless full. Or continuous Default: 1 T.SP 9999 T.SP 0.0 Returns to Hold back band size adjustable 0.1 to 150 units HB.V 150 HB.V OFF E.OP 2D3D E.OP 3E E.OP 3D E.OP 2E E.OP 2D E.OP NONE Set the segment to be adjusted Default: 1 To select operational mode of each segment Default: Ramp Adjusts ramp rate Default: 100 Target set point adjustable over the unit s range Default: Current main SP Hold back this function only appears for ramp operational once a value is set Default: off Event output options only appear when SP2A or SP3A modes set to E.OP Default: de-energise 15

16 English FUNCTION LIST (LEVEL P) RAMMER LEVEL P LEVL P Access Level P from Level 1. Press and hold Function Settings [Factory settings] shown in brackets Press or to change Press or to change ProG Program number [1] Add new programs (1 to 31) run Run Program [off] Program not running on Run program hold Pause program Edit del Delete program Edit ins Insert new program Edit CoPy Copy another program Edit PStE Paste copied program Fail Power failure recovery mode [rset] Reset to program start Cont Continue from interruption hold Hold at interruption (User re-start) St.V Program start value [PV] Process value SP Setpoint value SPru Ramp rate time units [hour] Ramp rate adjust in hours 60 s Ramp rate adjust in minutes Segment number [1] Add new segments (1 to 126) Function Sub-functions Settings [Factory settings] shown in brackets Press or to change Press or to change TyPE Define segment type SPr Ramp to next target setpoint SPrr [100] Setpoint ramp rate Units per hour/minute (0-9990) (as set at Spru above) t.sp (Segment target setpoint) adjustable over instrument s configured range hb.u Hold back [off] sets the permitted band size for the measured value to deviate from the ramp setpoint before the program is held back waiting for the measured value to catch up. (0.1 to 150 units) SoAK Hold setpoint for pre-set time [10] Sint Soak time, adjust in minutes (cont.-1440) x 0.1 StEP Step to new target setpoint (Set tsp as above) LooP Re-cycle program PCYC [1] Set number of program loops up to 999, or continuous loop CALL Call up another program by number to import into this program Sub.P (none) Number of Program called at Call above Edit del Delete segment Edit ins Insert new segment 16 See examples of EDIT procedures (page 18) Deleting a Program automatically re-numbers those programs with higher numbers Until memory full. See page 11 for further explanation and memory allocation table on page 17.

17 Function Press or to change Settings [Factory settings] shown in brackets Press or to change E.oP Event output [none] Function can be applied to each segment independently to trigger an output at the start of that segment for the duration of that segment. Setting blocked unless either or both outputs SP2A or SP3A have been configured as an Event Output in Level 2 or Level A respectively. 2d SP2A de-energised to mark event 2E SP2A energised to mark event 3d SP3A de-energised to mark event 3E SP3A energised to mark event 2d.3d SP2A and SP3A de-energised to mark event 2E.3d SP2A energised SP3A de-energised to mark event 2E.3E SP2A and SP3A energised to mark event 2d.3E SP2A de-energised SP3A energised to mark event To Return to: LEVL P Press and hold To Read % Programmer memory used: USEd Press and together in LEVL P / ProG % Memory Allocation Table Segment type Ramp Ramp with Holdback Soak Step Loops (1 3) Loops (4+) Call Event Output Program Header Maximum capacity: Memory required 4 Bytes 5 Bytes 2 Bytes 3 Bytes 1 Byte 2 Bytes 1 Byte 1 Byte 1 Byte 351 Bytes 31 Programs 126 Segments Examples: 1. 1 program of 58 Ramps and 58 Soaks 349 Bytes 2. 4 programs of 14 Ramps and 14 Soaks 340 Bytes programs of 2 Ramps and 1 Soak 341 Bytes 4. 2 programs of 10 Ramps, 10 Soaks, 2 Steps and 1 loop 136 Bytes Memory Full Indication Should the programmer memory capacity be reached during program configuration, the display will show FULL English 17

18 English RAMMING EXAMPLES KEY OR TOGETHER TO VIEW OR CHANGE SETTINGS 1 Program Edit Function Make copy of Program 1 and paste as new Program 2 EDIT COPY RUN OFF 3 secs ADD (next) 1 EDIT PSTE 3 secs RUN OFF ADD SURE YES SURE NO 3 secs LOOP SPR STEP 2 Program 1 now pasted as Program 2 KEY OR TO VIEW FUNCTIONS Program Segment Configuration See Program 3 illustrated on page 13 PCYC 1 SPRR 55 T.SP 30 T.SP 85 KEY Arrows drawn thus signify several key operations Programmer functions shown as white characters on black background have Default settings 2 SOAK SINT Program settings for functions: run; FAiL; St.U and SPru not shown, are all set to Default 1 SPR SPRR 10 S T.SP 137 HB.V OFF E.OP NONE

19 MECHANICAL INSTALLATION The Controller is designed to be sleeve mounted in a 1/16 DIN panel cutout with only the front panel rated to NEMA4/IP66, provided that: the panel is smooth and the panel cutout is accurate; the mounting instructions are carefully followed. DIN PANEL CUTOUT 1/16 DIN: 45.0mm +0.6 / -0.0 wide, 45.0mm +0.6 / -0.0 high Maximum panel thickness 9.5mm Minimum spacing 20mm vertical, 10mm horizontal MOUNTING To mount a Controller proceed as follows: 1 Check that the controller is correctly orientated and then slide the unit into the cutout. 2 Slide the panel clamp over the controller sleeve pressing it firmly against the panel until the controller is held firmly. 3 The controller front bezel and circuit board assembly can be unplugged from the sleeve. Grasp the bezel firmly by the recesses on each side and pull. A screwdriver can be used as a lever if required. 4 When refitting the bezel assembly it is important to press it firmly into the sleeve until the latch clicks in order to compress the gasket and seal to NEMA4X/IP66. CLEANING Wipe down with damp cloth (water only) DIMENSIONS CAUTION: The controller should be isolated before removing or refitting it in it s sleeve. Live circuits can hold a charge for short periods after isolation from voltage supply. Electrostatic precautions should be observed when handling the controller outside it s sleeve. Bezel* Behind Panel Overall Behind panel Width Height Width Height Length Length* ELECTRICAL INSTALLATION (See important Safety Information page 20) OUTPUT DEVICES WARNING: Three types of output device may be factory fitted to the controllers, and users must choose how to allocate these to outputs SP1 and SP2. (SP3 is always RLY). Check the model number and output configuration against the Output Options Table on page 8 before wiring the instrument and applying power. 1 Solid state relay drive (SSd1/SSd2) 6Vdc (nominal) 20mA max. To switch remote SSR (or logic) 2 Miniature power relay (rly/rly1/rly3) 2A/250V AC resistive, Form A/SPST contacts. 3 Analogue Output (AnLG) (isolated) Specify; 4 20mA 500Ω max +/- 0.1% fs typical 0 5Vdc 10mA (500Ω min) +/- 0.1% fs typical 0 10Vdc 10mA (1KΩ min) +/- 0.1% fs typical SUPPLY VOLTAGE V 50 60HZ 6.0VA (nominal) +/- 10% maximum permitted fluctuation WIRING THE CONNECTOR Prepare the cable carefully, remove a maximum of 8mm insulation and ideally tin to avoid bridging. Prevent excessive cable strain. Maximum recommended wire size: 32/0.2mm 1.0mm 2 (18AWG). INDUCTIVE LOADS To prolong relay contact life and suppress interference it is recommended engineering practice to fit a snubber (0.1uf/100 ohms) between relay output terminals. CAUTION: Snubber leakage current can cause some electro-mechanical devices to be held ON. Check with the manufacturers specifications. English Dimensions in mm * includes gasket 19

20 English * EN /CSA 22.2 No Compliance shall not be impaired when fitted to the final installation. Designed to offer a minimum of Basic Insulation only. The body responsible for the installation is to ensure that supplementary insulation suitable for Installation Category II or III is achieved when fully installed. To avoid possible hazards, accessible conductive parts of the final installation should be protectively earthed in accordance with EN61010 for Class 1 Equipment. Output wiring should be within a Protectively Earthed cabinet. Sensor sheaths should be bonded to protective earth or not be accessible. Live parts should not be accessible without the use of a tool. When fitted to the final installation, an IEC/CSA APPROVED disconnecting device should be used to disconnect both LINE and NEUTRAL conductors simultaneously. A clear instruction shall be provided not to position the equipment so that it is difficult to operate the disconnecting device. * EMC Immunity EMC immunity may be improved by fitting large Ferrite cores around the sensor cables at the point where they enter the cabinet and an earth bond is recommended. TYPICAL APPLICATION In this example the load temperature is monitored by a temperature transducer/transmitter which provides a 4 20mA input signal to the controller. The 4 20mA output has been allocated to SP1 to drive an SCR power controller providing a phase angle controlled output to the heater. F1 Fuse: 1A time lag type to IEC127. CSA/UL rating 250Vac F2 Fuse: High Rupture Capacity (HRC) Suitable for maximum rated load current S1 Switch: IEC/CSA/UL Approved disconnecting device. TYPICAL APPLICATION 4 20mA Transducer L Mains N Analogue power controller (+) ( ) S mA INPUT ( ) (+) Model 95B11P B F1 F2 Heater User configurable alarms L N 20

21 INPUT OPTIONS (+) Input ( ) (+) Spare Supply L N Standard Input Code OUTPUT: HARDWARE OPTIONS & TERMINATIONS Model Output Codes P English Thermocouple SSd (+) ( ) (+) Input ( ) (+) Spare Supply L N P Wire link RTD/PT100 2 wire 95 PA SSd (+) ( ) SSd (+) ( ) P (+) Input ( ) (+) Spare Supply L N RTD/PT100 3 wire AnLG (+) ( ) B11P = 4 20mA 95C11P = 0 5V 95D11P= 0 10V Input Spare Supply (+) ( ) (+) L N Linear Input Codes 95 PB= 4 20mA 95 PC= 0 5V 95 PD= 0 10V AnLG (+) ( ) SSd (+) ( ) B21P = 4 20mA 95C21P = 0 5V 95D21P= 0 10V Linear (transducer) input Relay = 1 SSd = 2 Analogue = B/C/D The analogue output always replaces the output on terminals 19 &

22 English INPUT SENSOR SELECTION Temperature sensors Thermocouples Description Sensor range Linearity tc b Pt-30%Rh/Pt-6%Rh 0 to 1800 C 2.0 * tc E Chromel/Con 0 to 600 C 0.5 tc J Iron/Constantan 0 to 800 C 0.5 tc K Chromel/Alumel -50 to 1200 C 0.25* tc L Fe/Konst 0 to 800 C 0.5 tc n NiCrosil/NiSil -50 to 1200 C 0.25* tc r Pt-13%Rh/Pt 0 to 1600 C 2.0* tc s Pt-10%Rh/Pt 0 to 1600 C 2.0* tc t Copper/Con -200 / 250 C 0.25* Resistance thermometer rtd 2/3 wire Pt100/RTD-2/3-200 / 400 C 0.25* Notes: 1 Linearity: 5-95% sensor range 2 * Linearity B:5 (70º C) K/N:1 >350 C exceptions: R/S: 5 <300 C T:1 <- -25 >150 C RTD/Pt100: 0.5 <-100 C Linear input (specification) Maximum recommended display resolution: 1mV / 500 Linear Input Typical accuracy Range 0 50mV +/- 0.1% -199 to mA +/- 0.1% -199 to /- 0.1% -199 to V +/- 0.1% -199 to 9999 Resistance thermometer RTD-2/Pt100 2 wire Standards: Bulb current: IEC 751:EN60751 (100Ω 0 C/138.5Ω 100 C Pt) 0.2mA maximum Linear process inputs see Linear input (specification) mv range: 0 to 50mV Applicable to all inputs SM = sensor maximum Calibration accuracy: ±0.25%SM ±1 C Sampling frequency: input 10Hz, CJC 2 sec. Common mode rejection: Negligible effect up to 140dB, 240V, 50-60Hz Series mode rejection: 60dB, 50-60Hz Temperature coefficient: 50ppm/ C SM typical Reference conditions: 22 C ±2 C, rated voltage after 15 minutes settling time. Output devices check configuration SSd1 and SSd2: solid state relay driver: To switch a remote SSR 6Vdc (nominal) 20mA non-isolated Miniature power relay: form A/SPST contacts (AgCdO) rly, rly1 and rly3: 2A/250ac resistive load Analogue output: 4 20mA 500Ω max +/- 0.1% fs typical 0 5Vdc 10mA (500Ω min) +/- 0.1% fs typical 0 10Vdc 10mA (1KΩ min) +/- 0.1% fs typical General Displays: Keypad: Upper, 4 Digits, high brightness green LED. 10mm (0.4 ) high. Lower, 4 Digits, high brightness Orange LED 9mm (0.35 ) high Digital range -199 to 9999 Hi-res mode to LED output indicators - flashing SP1 square, green; SP2/SP3 round, red 3 elastomeric buttons SPECIFICATION Thermocouple 9 types Standards: CJC rejection: External resistance: 22 IEC :EN :1 (0.05 / C) typical 100Ω maximum Environmental Humidity: Altitude: Installation: Pollution: Protection: EMC emission: EMC immunity: Ambient: Mouldings: Weight: Max 95% (non condensing) up to 2000M Categories ll and lll Degree ll NEMA 4X, lp66 (Front panel only) EN FCC Rules 15 subpart J Class A EN ºC ( F) flame retardant polycarbonate 180g (6.4 oz)

23 SAFETY AND WARRANTY INFORMATION INSTALLATION Designed for use: UL873 - only in products where the acceptability is determined by Underwriters Laboratories Inc. EN / CSA 22.2 No To offer a minimum of Basic Insulation only. Suitable for installation within Catagory II and III and Pollution Degree 2. SEE ELECTRICAL INSTALLATION Page 19 It is the responsibility of the installation engineer to ensure this equipment is installed as specified in this manual and is in compliance with appropriate wiring regulations. CONFIGURATION All functions are front selectable, it is the responsibility of the installing engineer to ensure that the configuration is safe. Use the program lock to protect critical functions from tampering. ULTIMATE SAFETY ALARMS Do not use SP2/SP3 as the sole alarm where personal injury or damage may be caused by equipment failure. WARRANTY CAL Controls warrant this product free from defect in workmanship and materials for three (3) years from date of purchase. 1 Should the unit malfunction, return it to the factory. If defective it will be repaired or replaced at no charge. 2 There are no user-servisable parts in this unit. This warranty is void if the unit shows evidence of being tampered with or subjected to excessive heat, moisture, corrosion or other misuse. 3 Components which wear, or damage with misuse, are excluded e.g. relays. 4 CAL Controls shall not be responsible for any damage or losses however caused, which may be experienced as a result of the installation or use of this product. CAL Controls liability for any breach of this agreement shall not exceed the purchase price paid E. & O.E. Copyright CAL Controls Ltd Not to be reproduced without prior written permission from CAL Controls Ltd. Whilst every effort has been made to ensure the accuracy of the specifications contained in this manual, due to our policy of continuous development, CAL Controls Ltd reserves the right to make changes without prior notice. CUSTOMER FEEDBACK It is CAL Controls aim to provide the best possible service to our customers. Feedback from our customers is therefore very important to ensure that we can make continual improvements to our products and services. Should you wish to register any issues with CAL please us at [email protected] or via the contact us section of our web site at Title your comments as Registered customer feedback or Registered customer complaint. Alternatively you can contact us on tel: +44 (0) or fax: +44 (0) English 23

24 CAL Controls CAL Controls Ltd Bury Mead Road, Hitchin, Herts, SG5 1RT. UK Tel: + 44 (0) Fax: + 44 (0) [email protected] CAL Controls Inc 1117 S.Milwaukee Avenue, Libertyville, IL USA Tel: (847) Fax: (847) [email protected] /02/0901/000M18/1